TECHNICAL FIELD
[0001] The present disclosure relates generally to structure control and, more particularly,
to applying, monitoring, and adjusting forces to a structure to control structure
contours.
BACKGROUND
[0002] When assembly, machining, manufacturing, and/or transporting large structures, it
is often necessary to ensure that the contours of the structure are consistent with
a desired structure design and/or associated tolerances. In the case of assembling
two or more large structures together to form a product, the importance of precisely
forming the respective structures is important for efficient manufacturing as well
as quality control. Assembling, machining, manufacturing, and/or transporting large
structures that meet desired design characteristics may be difficult due to internal
and external factors. For example, structure contour deviations may be realized due
to certain aspects of the desired design, the materials used, the manufacturing processes
used, the machinery used, and/or other factors. Additionally, a well-formed or assembled
structure may be subject to internal and/or external forces that cause changes in
the structure dimensions. Internally, a structure may include stresses induced during
manufacturing that alter the shape of the structure, even after manufacturing of the
structure is completed. Externally, the structure may be subjected to minor or even
significant changes induced by movement, shifts in the earth, transportation forces,
damage, other, or other forces.
[0003] The above considerations are compounded by modem manufacturing processes, wherein
a structure may be initially formed at one facility, and may then pass to or through
a number of other facilities. In some cases, the structure must be transported large
distances, even between multiple continents, between the time the first manufacturing
process is performed on the structure and the time at which the structure is a part
of, or is itself, a finished product. The transportation of the structure often introduces
new forces to the structure, possibly resulting in deformation of the structure. Furthermore,
even if deformation is not induced by the multiple possible transportations, a first
manufacturing facility may be aware of certain structure characteristics of which
a second manufacturing facility is unaware. Thus, a second facility may undertake
steps to collect data already collected at a first facility.
SUMMARY
[0004] It should be appreciated that this Summary is provided to introduce a selection of
concepts in a simplified form that are further described below in the Detailed Description.
This Summary is not intended to be used to limit the scope of the claimed subject
matter.
[0005] Systems and methods described herein provide for the determination of the contours
of a structure, an analysis of the contours and/or comparison of the contours to a
desired design and associated tolerances, and the controlled application and management
of forces to the structure for precision assembly, machining, and/or manufacturing.
Additionally, the contours of the structure may be controlled during transportation
to detect, and in some instances correct, deformation of the structure during transportation.
The embodiments disclosed herein provide for a contour control system that includes
contour measurement modules and force control modules to measure contours of a structure.
In addition to inputting data to the contour control system, the force control modules
can be controlled by the contour control system and/or a control system thereof. The
control system is operative to determine what forces, if any, should be applied to
a structure to obtain the desired contours. The control system also is operative to
control the force control modules to apply the determined forces, and to monitor the
applied forces to ensure that the forces remain within acceptable limits. If internal
or external factors result in any change in the structure and/or the forces sensed
by or applied by the contour control system, the contour control system is able to
compensate for these changes by adjusting the amount of force applied by the force
control modules. In this manner, the embodiments described herein allow for continuous
structure contour monitoring and control.
[0006] According to various embodiments, a contour control system is provided for controlling
a contour of a structure. The system includes a force control module operative to
apply a force to the structure, and a control system communicatively linked to the
force control module. The control system includes a processor functionally coupled
to a memory. The memory includes computer-readable instructions executable by the
processor to make the contour control system operative to obtain actual contour data
indicating the configuration and location of the contour, and to receive target contour
data associated with a desired structure. The target contour data includes data indicating
a desired location and configuration of the contour, and a pre-defined tolerance associated
with the desired location and configuration of the contour. The memory further includes
computer-readable instructions executable by the processor to make the contour control
system further operative to analyze the actual contour data and the target contour
data to determine if the location and configuration of the contour are within the
pre-defined tolerance of the desired location and configuration of the contour, and
to determine a force to be applied by the force control module to control the location
and configuration of the contour.
[0007] According to other embodiments described herein, a method for controlling a contour
of a structure is provided. The method includes obtaining, with a measurement device,
actual contour data. The actual contour data indicates at least one of a configuration
of the contour and a location of the contour. The method further includes receiving,
at a contour control system, target contour data associated with a desired structure.
The target contour data includes data indicating at least one of a desired location
of a contour, and a desired configuration of the contour. Additionally, the target
contour data includes a tolerance associated with the contour. The method also includes
analyzing the actual contour data and the target contour data to determine if the
contour is consistent with the target contour data, and determining a force to be
applied by a force control module to control the at least one of the location of the
contour and the configuration of the contour. The method also includes activating
the force control module to apply the determined force to the structure to control
the at least one of the location of the contour and the configuration of the contour,
and monitoring the structure to determine if an additional force should be applied
to control the at least one of the location of the contour and the configuration of
the contour.
[0008] According to further embodiments described herein, a method for controlling a contour
of a structure is provided. The method includes receiving, at a contour control system,
stored load data associated with the structure. The stored load data indicates a force
applied to the structure by a force application device to control the contour, and
a tolerance associated with the force. The method further includes obtaining, using
a force sensor of a force control module, a structure load data indicating a force
between the structure and the force control module. The method also includes analyzing
the structure load data and the stored load data to determine if the structure load
data is consistent with the stored load data and the tolerance, and determining a
force to be applied by a force control module to match the stored load data and the
tolerance. The method includes activating the force control module to apply the determined
force to the structure, and monitoring the structure to determine if an additional
force should be applied to the structure.
[0009] The features, functions, and advantages that have been discussed can be achieved
independently in various embodiments of the present disclosure or may be combined
in yet other embodiments, further details of which can be seen with reference to the
following description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010]
FIGURE 1 is a block diagram showing elements of a contour control system, according to an
exemplary embodiment of the present disclosure.
FIGURE 2 is block diagram showing elements of a control system, according to an exemplary
embodiment of the present disclosure.
FIGURE 3A schematically illustrates a force control module ("FCM"), according to an exemplary
embodiment of the present disclosure.
FIGURE 3B illustrates an FCM, according to another exemplary embodiment of the present disclosure.
FIGURE 3C illustrates a portion of a surface of a multi-cell FCM, according to an exemplary
embodiment of the present disclosure.
FIGURE 4A illustrates a structure support cradle, according to an exemplary embodiment of the
present disclosure.
FIGURES 4B-4D illustrate additional details of the structure support cradle and the FCM, according
to exemplary embodiments of the present disclosure.
FIGURE 5A illustrates placement of contour measurement modules, according to an exemplary embodiment
of the present disclosure.
FIGURE 5B illustrates placement of FCM's and the structure support cradle, according to an
exemplary embodiment of the present disclosure.
FIGURE 6 schematically illustrates a method for using the contour control system, according
to an exemplary embodiment of the present disclosure.
DETAILED DESCRIPTION
[0011] The following detailed description is directed to systems and methods for controlling
the shape,
e.g. the contours, of a structure, for example, an aerospace structure. In some embodiments,
the contours of the structure are controlled during manufacturing, machining, assembly,
and/or transportation. The embodiments described below provide a contour control system
capable of using contour measurement devices to determine the contours of a structure,
compare the structure contours with target contour data associated with a desired
structure, and use a system of force control modules and support structures to apply
forces to the structure to control the contours of the structure. Additionally, the
contour control system includes, in some embodiments, a control system operative to
monitor and control the forces applied to the structure by the force control modules
and/or support structures.
[0012] Using these embodiments, precise forces may be applied to the structure at various
locations to control the contours of the structure at a desired time, for example,
during manufacturing and/or assembly of the structure. The contour control system
is operative to continuously monitor and adjust the contours of the structure, thereby
ensuring that the structure contours are maintained at or near an optimal configuration
during manufacturing, transportation, assembly, or other operations, during which
internal or external forces might otherwise shift the structure contours out of the
desired configurations. In some embodiments, the forces applied by the force control
modules are continuously monitored and adjusted to ensure that structural and/or material
constraints are not exceeded and/or to prevent undesirable material and/or structure
deformation.
[0013] In the following detailed description, references are made to the accompanying drawings
that form a part hereof, and which are shown by way of illustration, specific embodiments,
or examples. Referring now to the drawings, in which like numerals represent like
elements through the several figures, aspects of a contour control system will be
described.
FIGURE 1 shows a contour control system
100, according to an exemplary embodiment of the present disclosure. The contour control
system
100 includes a control system
102 that is communicatively linked to one or more force control modules
104 ("FCM's"), each of which is configured to apply a force to support, level, deform,
manipulate, and/or otherwise control the contours of a structure
106. Throughout this disclosure, embodiments will be described in the context of the structure
106 being an aerospace structure such as fuselage portion. It should be understood, however,
that the technologies and concepts disclosed herein are applicable to other structures
including, but not limited to, ships, hulls, automobile chassis, other vehicle components,
and building or other architectural structures. In some embodiments, the control system
102 also is communicatively linked to one or more contour measurement modules
108 ("CMM's"), each of which is configured to measure the contours of the structure
106.
[0014] As will be described in greater detail below with reference to
FIGURES 3A-6, according to some embodiments, the FCM's
104 include one or more air cushion contact pads configured to selectively apply a force
to the structure
106. For example, the air cushion pads can be inflated to increase pressure within the
air cushion pads, thereby applying a force to surfaces or points of the structure
106 in contact with the air cushion pads. Additionally, or alternatively, the air cushion
pads can be deflated to decrease pressure within the air cushion pads, thereby reducing
forces applied to the surfaces or points of the structure
106 in contact with air cushion pads. Suitable examples of the air cushion pads include,
but are not limited to, various air load modules sold by AeroGo of Seattle, WA under
the mark AEROGO LOAD MODULE™. It should be understood that air cushion pads and/or
air load modules can be configured as flat pads, or can be molded to match or approximate
a particular surface.
[0015] In some embodiments, the FCM's
104 include one or more vacuum cups configured to selectively apply a force to the structure
106. For example, the vacuum cups can be activated to increase negative pressure inside
the vacuum cups at surfaces or points of the structure
106 in contact with the vacuum cups, thereby generating pulling forces at the surfaces
or points of the structure
106. Additionally, or alternatively, the vacuum cups can be deactivated to decrease the
negative pressure inside the vacuum cups, thereby reducing pulling forces at the surfaces
or points of the structure
106. Suitable examples of the vacuum cups include, but are not limited to, various vacuum
cups sold by Anver Corp. of Hudson, MA under the mark ANVER®, including model numbers
VC119Q-GR and VC125Q-2-GR.
[0016] In some embodiments, the FCM's
104 include one or more structure support cradles configured to support the structure
106, thereby applying static forces to the surfaces or points of the structure
106. In some embodiments, the structure support cradle is equipped with and/or complimented
by one or more air cushion contact pads and/or vacuum cups. Although not illustrated,
it will be appreciated that the contour control system
100 may include air compressors, pressure sensors, air flow regulators, vacuum pumps,
air lines, vacuum lines, and power supplies to operate and/or control the various
components of the contour control system
100, including the FCM's
104 and structure support cradles and/or components thereof. It should be appreciated
that the structure
106 may be any part, tool, or other structure that requires leveling and/or machining,
and is not limited to an airplane fuselage or other aerospace structure.
[0017] As will be described in greater detail below with reference to
FIGURE 5A, according to some embodiments, the CMM's
108 include one or more measurement devices configured to measure the location of and/or
a configuration of one or more surfaces, surface contours, and/or surface points of
the structure
106. In some embodiments, the CMM's
108 include contactless measuring devices such as, for example, a laser radar or laser
tracking device. Suitable examples of a CMM
108 include, but are not limited to, high-speed contactless laser scanners sold by Leica
Geosystems, part of the Hexagon Group of Stockholm, Sweden, for example a high speed
laser tracker sold under the mark LEICA ABSOLUTE TRACKER™, and laser radar devices
sold by Metris, USA of Brighton, MI under the mark METRIS®, including model numbers
MV224 and MV260. In some embodiments, the CMM's
108 include contact measurement devices such as, for example, actuators and precision
drive systems capable of measuring exact location of surface point locations of a
structure. In some embodiments, the CMM's
108 include a combination of contactless and contact measurement devices. It should be
appreciated that the CMM's
108 may scan an entire surface of the structure
106, all surfaces of the structure
106, some contours of the structure
106, all contours of the structure
106, and/or selected points of the structure
106. In some embodiments, the CMM's
108 monitor certain points of the structure
106 that adequately illustrate the contours of the structure
106. The determination as to how many points, contours, and/or surfaces of the structure
106 will be monitored can be made using any known techniques, for example, finite element
analysis.
[0018] The control system
102 may include any type of computing device capable of executing a contour control application
110. The contour control application
110 includes computer executable instructions executable by the control system
102 and/or a data processing device associated with the control system
102. Execution of the contour control application
110 makes the control system
102 operative to determine structure contours, for example, by retrieving and/or receiving
data from the CMM's
108 or other devices. Execution of the contour control application
110 makes the control system
102 further operative to determine if data representing the actual structure contours
("actual contour data) of a structure
106 is consistent with data representing desired or targeted design contour data ("target
contour data") of a structure
106 and/or associated tolerances. Additionally, execution of the contour control application
110 makes the control system
102 further operative to apply, monitor, and/or adjust forces applied to the structure
106 via the FCM's
104, as described with respect to various exemplary embodiments below. In some embodiments,
the functions of the control system
102 are provided by a desktop computer, a notebook computer, a netbook, a personal data
assistant, a smart phone, a hand-held portable computing device, or another computing
device. The architecture associated with an exemplary control system
102 is described below with reference to
FIGURE 2.
[0019] The control system
102 and/or the contour control application
110 are communicatively linked to a contour data repository
112 ("CDR") configured to store load data
114 and/or target contour data
116. The load data
114 includes data corresponding to forces measured at and/or applied by the FCM's
104. The target contour data
116 includes data corresponding to and/or indicating targeted or desired contour data
associated with the structure
106. The target contour data
116 can include, for example, a dataset representing desired design contour data of a
structure
106 and/or associated tolerances. In some embodiments, the CDR
112 includes a database in communication with the control system
102 and/or the contour control application
110. In some embodiments, the CDR
112 includes a data storage location associated with the control system
102. Thus, it should be appreciated that the load data
114 and/or the target contour data
116 may be stored within the control system
102 and/or at a remote location accessible by the control system
102 and/or the contour control application
110.
[0020] The FCM's
104, the CMM's
108, and the control system
102 are configured in some embodiments to communicate with one another via a direct link
and/or via a communications network
118. In some embodiments, the network
118 includes a wireless network such as, but not limited to, a Wireless Local Area Network
("WLAN") such as a WIFI® network, a Wireless Wide Area Network ("WWAN"), a Wireless
Personal Area Network ("WPAN") such as BLUETOOTH, a Wireless Metropolitan Area Network
("WMAN") such a WIMAX® network, a cellular network, a satellite network, combinations
thereof, and the like. In some embodiments, the network
118 includes a wired network such as, but not limited to, a wired Wide Area Network ("WAN")
such as the Internet, a wired Local Area Network ("LAN") such as an intranet, a wired
Personal Area Network ("PAN"), and/or a wired Metropolitan Area Network ("MAN"). In
some embodiments, the network
118 includes one or more wired networks and/or wireless networks in communication with
the Internet. Thus, some embodiments of the network
118 include a combination of wired and/or wireless technologies to provide connectivity
between the FCM's
104, the CMM's
108, and the control system
102.
[0021] Turning now to
FIGURE 2, the control system
102 will be described, according to an exemplary embodiment of the present disclosure.
The illustrated control system
102 includes a data storage device
202 ("memory"), a data processing unit
204 ("processor"), and a network interface
206, each of which is operatively connected to a system bus
208 that enables bi-directional communication between the memory
202, the processor
204, and the network interface
206. Although the memory
202, the processor
204, and the network interface
206 are illustrated as unitary devices, some embodiments of the control system
102 include multiple processors, multiple memory devices, and/or multiple network interfaces.
[0022] The processor
204 may include a standard central processor that performs arithmetic and logical operations,
a more specific purpose programmable logic controller ("PLC"), a programmable gate
array, or other type of processor known to those skilled in the art and suitable for
controlling the operation of the control system
102. Data processing devices such as the processor
204 are well-known in the art, and therefore are not described in further detail herein.
[0023] Although the memory
202 is illustrated as communicating with the processor
204 via the system bus
208, in some embodiments, the memory
202 is operatively connected to a memory controller (not shown) that enables communication
with the processor
204 via the system bus
208. Furthermore, although the memory
202 is illustrated as residing at the control system
102, it should be understood that the memory
202 may include a remote data storage device accessed by the control system
102, for example the CDR
112. Therefore, it should be understood that the illustrated memory
202 can include one or more databases or other data storage devices communicatively linked
with the control system
102.
[0024] The network interface
206 enables the control system
102 to communicate with other networks or remote systems, for example, the FCMS's
104, the CMM's
108, one or more elements of the network
118, the CDR
112, databases, other devices, combinations thereof, and the like. Examples of the network
interface
206 include, but are not limited to, a modem, a radio frequency ("RF") or infrared ("IR")
transceiver, a telephonic interface, a bridge, a router, and a network card. Thus,
the control system
102 is able to communicate with the network
118 and/or various components of the network
118. As explained above, the network
118 includes, in some embodiments, a WLAN, a WWAN, a WPAN, a WMAN, a WAN, a LAN, a PAN,
a MAN, and/or combinations thereof. The control system
102 also may access a public switched telephone network ("PSTN").
[0025] The memory
202 is configured for storing computer executable instructions that are executable by
the processor
204 to make the control system
102 operative to provide the functions described herein. While embodiments will be described
in the general context of program modules that execute in conjunction with application
programs that run on an operating system on the control system
102, those skilled in the art will recognize that the embodiments also may be implemented
in combination with other program modules. For purposes of clarifying the disclosure,
the instructions are described as a number of program modules. It must be understood
that the division of computer executable instructions into the illustrated and described
program modules may be conceptual only, and is done solely for the sake of conveniently
illustrating and describing the control system
102 and the functions performed thereby. In some embodiments, the memory
202 stores all of the computer executable instructions as a single program module. In
some embodiments, the memory
202 stores part of the computer executable instructions, and another system and/or data
storage device stores other computer executable instructions. As such, it should be
understood that the control system
102 may be embodied in a unitary device, or may function as a distributed computing system
wherein more than one hardware and/or software modules provide the various functions
described herein.
[0026] For purposes of this description, "program modules" include applications, routines,
programs, components, software, software modules, data structures, and/or other types
of structures that perform particular tasks or implement particular abstract data
types. Moreover, those skilled in the art will appreciate that embodiments may be
practiced with other computer system configurations, including hand-held devices,
multiprocessor systems, microprocessor-based or programmable consumer electronics,
minicomputers, mainframe computers, and the like. The embodiments may also be practiced
in distributed computing environments where tasks are performed by remote processing
devices that are linked through a communications network. In a distributed computing
environment, program modules may be located in both local and remote memory storage
devices. The program modules described herein may be stored at a data storage device
such as the memory
202.
[0027] The memory
202 may include any type of computer-readable media including volatile and non-volatile,
removable and non-removable media implemented in any method or technology for storage
of information such as computer-readable instructions, data structures, program modules,
or other data. Computer-readable media further includes, but is not limited to, RAM,
ROM, Erasable Programmable ROM ("EPROM"), Electrically Erasable Programmable ROM ("EEPROM"),
flash memory or other solid state memory technology, CD-ROM, digital versatile disks
("DVD"), or other optical storage, magnetic cassettes, magnetic tape, magnetic disk
storage or other magnetic storage devices, or any other medium that can be used to
store the desired information and which can be accessed by the contour control system
100 and/or the contour control application
110.
[0028] In some embodiments, the memory
202 stores the contour control application
110. The contour control application
110 is executable by the processor
204 to retrieve and/or receive data associated with the CMM's
108, for example structure surface contour measurements ("actual contour data") or other
data. Additionally, the contour control application
110 is executable by the processor
204 to retrieve and/or receive data associated with the FCM's
104, for example, loads sensed at the FCM's
104 and/or forces applied by the FCM's
104. As explained above, the contour control application
110 is executable by the processor
204 to retrieve, receive, and/or analyze the data associated with the FCM's
104 and/or the CMM's
108, the load data
114, the target contour data
116, other data, combinations thereof, and the like. The load data
114 may be stored at the CDR
112, the memory
202, and/or another data storage device and associated with a particular structure
106.
[0029] In some embodiments, the load data
114 includes data indicating forces measured at the FCM's
104 of the contour control system
100. In some embodiments, a first manufacturing facility determines the load data
114 associated with the structure, stores the load data
114 at a data storage location such as the CDR
112, associates the load data
114 with the structure
106, and then transports the structure
106 to a second manufacturing facility. The second manufacturing facility retrieves the
load data
114 from the data storage location and uses the load data
114 to control the contours of the structure
106. For example, a contour control system
100 of the second manufacturing facility may apply the load data
114 to the structure
106, i.e., the contour control system can configure the FCM's
104 of the system to reproduce the stored load data
114, thereby avoiding determining how to configure the FCM's
104 to provide the desired contours of the structure
106. These and other exemplary embodiments are described in more detail herein.
[0030] In some embodiments, the memory
202 includes one or more storage locations for the load data
114 and/or the target contour data
116. As mentioned above, the load data
114 and/or the target contour data
116 may be stored at an alternative data storage device such as, for example, the CDR
112. Thus, the memory
202 may store some, all, or none of the load data
114 and/or the target contour data
116. The memory
202 also stores other data
210. The other data
210 includes data and instructions. For example, the other data
210 can include operating statistics, authentication data, user information, manufacturing
statistics, quality control data and applications, data caches, data buffers, user
interface applications, additional programs, applications, program modules, data,
combinations thereof and the like.
[0031] In some embodiments, the memory
202 includes an operating system
212. Examples of operating systems include, but are not limited to, WINDOWS, WINDOWS CE,
and WINDOWS MOBILE from MICROSOFT CORPORATION, LINUX, SYMBIAN from SYMBIAN LIMITED,
BREW from QUALCOMM CORPORATION, MAC OS from APPLE CORPORATION, and FREEBSD operating
system. Although not illustrated, the control system
102 also may include a random access memory ("RAM") and a read-only memory ("ROM"). The
ROM can store, for example, a basic input/output system ("BIOS") containing the basic
routines that help to transfer information between elements within the control system
102, such as during startup. In some embodiments, the control system
102 further includes a mass storage device for storing additional and/or alternative
application programs and program modules. The mass storage device can be connected
to the processor
204 through a mass storage controller (not shown) connected to the bus
208. The mass storage device and its associated computer-readable media provide non-volatile
storage for the control system
102. It should be appreciated by those skilled in the art that computer-readable media
can be any available media that can be accessed by the control system
102, including the various types of computer-readable media set forth above. The control
system
102 also may include an input/output controller (not illustrated) for receiving and processing
input from one or more input devices such as, for example, a keyboard, mouse, electronic
stylus, and the like (not shown). Similarly, an input/output controller may provide
output to a display screen, a printer, or other type of output device (not shown).
[0032] Turning now to
FIGURE 3A, an FCM
104 will be described, according to an exemplary embodiment of the present disclosure.
The FCM
104 is configured to provide a moveable support to control the contours of the structure
106. Additionally, the FCM
104 is configured to apply forces to the structure
106 to maintain or adjust the contours of the structure
106. In some embodiments of the contour control system
100, a number of FCM's
104 are positioned at supporting locations around the structure
106. The precise number and positions of the supporting locations may be determined using
any known engineering techniques such as finite element analysis. For example, if
the structure
106 is a rigid structure that has a relatively uniform mass distribution and relatively
little weight, then relatively fewer FCM's
104 may be used than would be used if the structure
106 is a heavy flexible structure with uneven mass distribution. In the first scenario,
the FCM's
104 may be evenly spaced around or under the structure
106, while in the latter scenario, the FCM's
104 may be grouped more closely under the heavier portions of the structure
106 to limit the deflection of the structure
106 between the FCM's
104. Similarly, if the structure
106 is a rigid structure, FCM's
104 may be employed to apply forces to the top or sides of the structure to assist in
form-fitting the structure
106 to a cradle or other manufacturing assembly device that also relies upon gravity
to maintain the structure
106 in a desired position for manufacturing and/or assembly. One example of this implementation
will be shown and discussed below with reference to
FIGURE 4A. In some embodiments, the FCM's
104 include "smart jacks" and/or other devices disclosed in co-pending
U.S. Pat. App. Ser. No. 11/944,872, entitled "Controlled Application of External Forces to a Structure for Precision
Leveling and Securing," which is hereby incorporated by reference in its entirety.
[0033] The illustrated FCM
104 includes a load surface
300. The load surface
300 is configured to contact a surface of the structure
106 to bear a force and/or selectively apply a force to the structure
106. In some embodiments, the load surface
300 includes a structure contact surface layer
302 disposed above a load sub-surface layer
304, though this is not necessarily the case. Furthermore, the load surface
300 includes, in some embodiments, additional and/or alternative layers. In some embodiments,
one or more layers
302, 304 of the load surface
300 include an air cushion contact pad configured to be selectively activated to apply
a force to a surface of the structure
106. In some embodiments, one or more layers
302, 304 of the load surface
300 includes a rubber contact pad configured to contact a surface of the structure
106. The load surface
300 is configured to support the structure and/or to apply a static or dynamic force
to a surface of the structure
106. Other configurations of the load surface
300 are possible, and are contemplated. For example, one or more layers
302, 304 of the load surface
300 may include a vacuum cup for applying a force to a surface of the structure
106. The vacuum cup embodiment of the FCM
104 is configured to pull a surface of the structure to support the structure
106 and/or to deform the structure
106 to control one or more structure contours, as discussed above.
[0034] In some embodiments, the FCM
104 includes a support structure
306, which can include a composite, aluminum, or other material that functions as a support
sub-structure for the load surface
300. The support structure
306, if included, can perform several functions. For example, the support structure
306 can provide rigidity for the load surface
300, particularly if the load surface
300 is soft and/or pliable, as is often the case with a rubber pad, an air cushion layer,
and/or a vacuum cup layer. Additionally, the support structure
306 can be configured to bear forces transferred between the FCM
104 and the surface of the structure
106 to reduce strain on the load surface
300 and/or the layers
302, 304 thereof. In some embodiments, the FCM
104 includes a centering mechanism
308. The centering mechanism
308 may include, but is not limited to, a split gimbal self-centering support bearing,
a ball and socket joint, or other centering mechanisms.
[0035] The FCM
104 also can include a position adjusting mechanism
310 for adjusting the position of the load surface
300 with respect to the surface of the structure
106. The position adjusting mechanism
310 includes, in some embodiments, a height adjustment mechanism for adjusting the height
of the FCM
104 and/or components thereof. The height adjustment mechanism can include a servomotor,
a hydraulic actuator, a pneumatic actuator, pneumatically driven pistons or other
devices, threaded sleeves and reciprocally threaded shafts, adjustable parallel tooling,
adjustable jacks, other height adjustment mechanisms, and the like. Considering, for
a moment, the height of the FCM
104 as being along a 'z-axis,' the position adjusting mechanism
310 also includes, in some embodiments, mechanisms for adjusting the position of the
load surface
300 in the `x-axis' and the 'y-axis.' The FCM
104 therefore may include various devices for adjusting the position of the load surface
300 with respect to a surface of the structure
106. The position adjusting mechanism
310 may be driven by a drive
312, which may include motors, air lines, vacuum lines, switches, pressure controllers,
jacks, gears, electronic controls, combinations thereof, and the like.
[0036] FIGURE 3B illustrates an FCM
104, according to another exemplary embodiment of the present disclosure. The FCM
104 includes a lower support plate
314. In some embodiments, the lower support plate
314 mates with an upper support plate (not illustrated in
FIGURE 3B), though this is not necessarily the case. The lower support plate
314 includes connection mechanisms
316 for connecting the FCM
104 to a desired structure, for example, a support cradle, as will be shown and discussed
below with reference to
FIGURES 4B-4D. The connection mechanisms
316 are illustrated as apertures for receiving a rod, screw, bolt, rivet, and/or another
connector, though this embodiment is exemplary and should not be construed as being
limiting in any way. The lower support plate
314 includes a linear bearing
318 through which a connection rod
320 passes. The linear bearing can be any known linear bearing including, but not limited
to, a closed linear pillow block bearing. The connection rod
320 is connected to the load surface
300 or a component thereof via the centering mechanism
308 on one end, and to a force sensor
322, for example, a force sensing actuator, on the other end.
[0037] The force sensor
322 may be a load cell, a pressure gauge, a piezoelectric sensor, or any other type of
force sensor capable of measuring the quantity of force applied to the structure
106 by the FCM
104 and/or to the FCM
104 by the structure
106. Suitable examples of the force sensor
322 include, but are not limited to, force measuring actuators sold by Exlar Corporation
of Chanhassen, MN under the mark EXLAR®, including model numbers GSX30, GSX40, GSX50,
GSX60, IS30 and IS40. The force sensor
322 may be located as shown, or may be located in any other suitable position for sensing
and/or measuring the force between the FCM
104 and the structure
106. In embodiments in which the force sensor
322 include a force measuring capability, the force sensor
322 can be used to provide the FCM
104 with the ability to measure a force measured between the FCM
104 and a structure in contact with the FCM
104, for example, the structure
106. The forces sensed by the FCM
104 can be reported to the contour control system
100 to be used to determine the contours of the structure
106. Thus, the contour control system
100 is configured to use the CMM's
108 and/or the FCM's
104 to determine the contours of the structure
106.
[0038] The FCM
104 can be activated via the control system
102 or another device. Thus, the use of a force sensing actuator
322 is merely exemplary and should not be construed as being limiting in any way. Additional
and alternative embodiments are described herein. Although not illustrated in
FIGURE 3B, the FCM
104 may be coupled to a position adjusting mechanism
310 and/or a drive
312, as discussed with reference to
FIGURE 3A. The position adjusting mechanism
310 and/or the drive
312 are operative to adjust the position of the FCM
104 with respect to the structure
106, and may be controlled by the control system
102 and/or the contour control application
110 as explained herein. Communications between the contour control application
110 and the FCM
104 may be conducted over one or more wired and/or wireless networks or network components,
or may be via a direct wired and/or wireless link. Regardless of the type of connection
used, the contour control application
110 is operative to send control commands to the FCM
104 or a component thereof, for example, the position adjusting mechanism
310 and/or the drive
312, to control the position of and/or a force applied by the FCM
104 to the structure
106. Furthermore, the contour control application
110 is operative to receive data indicating the force applied to or by the FCM
104, and to use that data to determine whether the position of and/or the force applied
by the FCM
104 should be adjusted to control a contour of the structure
106. Thus, the contour control application
110 is able to control the amount of force applied to the structure
106 by the FCM
104 and/or the location of the force applied to the structure
106 by the FCM
104 to control one or more contours of the structure
106.
[0039] FIGURE 3C illustrates a portion of a surface of an FCM
104, according to another exemplary embodiment of the present disclosure. The FCM
104 illustrated in
FIGURE 3C employs an array of air pressure application cells
324. Each of the air pressure application cells
324 can include contact surfaces
326 that contact the surface of the structure
106. The contact surfaces
326 can include pliable or malleable ridges so that the contact surfaces
326, and therefore the FCM
104, mold to the surface of the structure
106. Thus, each air pressure application cell
324 can be sealed against the structure so that air pressure can be controlled at the
surface
106 corresponding to each of the air pressure application cells
324. In one contemplated embodiment, the contact surfaces
326 include compressible blue rubber baffles that include .200 inches in compressible
height. It should be understood that this embodiment is exemplary, and that other
materials and compressible heights are both possible and contemplated.
[0040] As illustrated, each of the air pressure application cells
324 further can include a pressurized air intake port
328 and a pressure sensor (not visible). The pressure sensors measure pressure at each
air pressure application cell
324. The measured pressure can be transmitted or fed back to the control system
102, which can analyze the measured pressure as force or load data
114. The control system
102 can be configured to control the flow of air to each of the air pressure applications
cells 324 to regulate, change, activate, and/or deactivate air pressure at each individual
air pressure application cell
324. Although not illustrated in
FIGURE 3C, the air pressure application cells
324 also can include a position adjustment device and a drive, which can function in
a manner similar to the position adjustment device
310 and the drive
312 illustrated and described with reference to
FIGURE 3A. In one embodiment, each air pressure application cell
324 includes a ball screw drive, mounted under each air pressure application cell
324, for adjusting the position of the air pressure application cell
324. An FCM
104 constructed in accordance with
FIGURE 3C can be used to evenly distribute support forces over a large surface of the structure
106, and to help avoid destructive single point loads that may be applied to the structure
106 if using other support structures.
[0041] FIGURE 4A illustrates a structure support cradle
400 ("cradle"), according to an exemplary embodiment of the present disclosure. The cradle
400 includes a contact surface
402 that contacts a surface of the structure
106. In some embodiments, the cradle
400 includes one or more cradle modules
404 that collectively join together to provide the support surface
402 and the other structures described herein. It some embodiments, the cradle
400 includes a substantially unitary structure. Thus, it should be understood that the
cradle
400 need not include the cradle modules
404, and that the illustrated embodiment is merely exemplary and should not be construed
as being limiting in any way.
[0042] In some embodiments, the cradle modules
404 include ribs
406 and apertures
408. Ribs
406 may be included to provide or increase rigidity and support for the support surface
402, but are not always necessary and therefore may be omitted in some embodiments. As
illustrated, the cradle
400 can include one or more FCM's
104. In some embodiments, the FCM's
104 are disposed such that the load surfaces
300 of respective FCM's
104 are flush with the contact surface
402, below the contact surface
402, or above the contact surface
402. The illustrated configuration,
i.e., the load surfaces
300 of respective FCM's
104 being disposed above the contact surface
402, is provided for purposes of clarifying the concepts of the present disclosure and
should not be construed as being limiting in any way. In some embodiments, the contact
surface
402 supports a surface of the structure
106 and the FCM's
104 are used to measure forces at the locations of the FCM's
104 and/or to apply additional support or forces to the surface of the structure
106 to control contours of the structure
106.
[0043] Turning now to
FIGURE 4B, additional details of the cradle
400 and the FCM's
104 are explained.
FIGURE 4B illustrates placement of an FCM
104 according to an exemplary embodiment of the present disclosure. In the illustrated
embodiment, the FCM
104 includes the lower support plate
314 as described above with reference to
FIGURE 3B. The FCM
104 also includes the upper support plate
410 mentioned above, which is configured to be connected to the lower support plate
314 using connectors
412, 414. The illustrated connectors
412, 414, as well as the numbers of connectors and the placement thereof, are merely exemplary
and should not be construed as being limiting in any way. The FCM
104 is configured to be connected to a cradle module
404 via the connectors
412, 414 and an FCM attachment plate
416. The FCM attachment plate
416 includes a throughhole
418 through which the connector
412 passes, though this method of attaching the FCM attachment plate
416 to the FCM
104 is merely exemplary. As illustrated, the FCM
104 can be connected between two cradle modules
404 using the connectors
412, 414 and the FCM attachment plates
416.
[0044] Additional views of the FCM
104 and the cradle modules
404 are provided in
FIGURES 4C-4D. FIGURE 4C illustrates a perspective view of the FCM
104 and cradle modules
404 of
FIGURE 4B.
FIGURE 4D illustrates a top view of three FCM's
104 attached between two cradles
400. In
FIGURE 4D, the support surfaces
402 of the cradles
400 are visible, as are the load surfaces
300 of the FCM's
104. It should be understood that the load surfaces
300 may have alternative shapes and configurations, and that the illustrated embodiment
is merely exemplary. In
FIGURE 4D, only the load surfaces
300 of the FCM's
104 are visible, though this is not necessarily the case.
[0045] Turning now to
FIGURE 5A, placement of the CMM's
108 with respect to the structure
106 is illustrated, according to an exemplary embodiment of the present disclosure. Although
not illustrated in
FIGURE 5A, it should be understood that the structure
106 can be supported by support structures such as, for example, the cradle
400. In the illustrated embodiment, a radial array of CMM's
108 are disposed at the surface of the structure
106. In the illustrated embodiment, eight CMM's
108 are included, though other numbers of CMM's
108 are possible and are contemplated. While the CMM's
108 are illustrated as being adjacent the surface of the structure
106, it should be understood, as explained above, that in some embodiments, the CMM's
108 include one or more laser radar or laser tracker devices placed proximate to an inner
or outer surface of the structure
106. The effective range of some laser radar and/or laser tracker devices can be between
one and sixty meters, or even greater. Therefore, the CMM's
108 may be placed a substantial distance away from the structure
106.
[0046] Thus, the number of the CMM's
108, as well as the respective locations and placement of the CMM's
108, can be determined based upon the needs associated with the structure
106 and/or the limitations and/or needs of a particular application of the contour control
system
100 and/or the type of device used to provide the functions of the CMM
108. For example, for low tolerance applications,
i.e., for applications where high accuracy and precision are required, more CMM's
108 may be used than are used for relatively high tolerance applications wherein a relatively
lower level of accuracy and precision are required. Again, the exact number of CMM's
108 and the placement thereof will vary depending upon the application. With an understanding
of the concepts of the present disclosure, one of ordinary skill in the art will be
able to determine the number of CMM's
108 to be employed and the respective placement thereof, without undue experimentation.
[0047] As mentioned above, the CMM's
108 can determine the locations and/or configurations of one or more surfaces of the
structure
106, one or more surface contours of the structure
106, and/or one or more points of the structure
106. The CMM's
108 can output these determined locations and/or configurations as data that is interpretable
by the contour control system
100 as indicating the locations and/or configurations of the contours of the structure
106. The contour control system 100 may compare the determined locations and/or configurations
of the contours of the structure 106 to the desired structure contours and can determine
forces that should be applied to the structure 106 to manipulate the structure 106
to generate the desired structure contours.
[0048] Turning now to
FIGURE 5B, placement of the FCM's
104 and the cradle
400 with respect to the structure
106 is illustrated, according to an exemplary embodiment of the present disclosure. As
illustrated, the structure
106 is supported by the cradle
400. Although not visible in
FIGURE 5B, the cradle
400 includes a number of FCM's
104, for example the FCM's
104 illustrated in
FIGURES 3A-4D. Additionally, a number of FCM's
104 are disposed at several locations around the surface of the structure
106. In the illustrated embodiment, the FCM's
104 include vacuum cups and the cradle
400 includes seven FCM's
104 that include air cushion contact pads. Additional and/or alternative FCM's
104 are possible and are contemplated.
[0049] As mentioned above, the contour control application
110 is operative to compare the actual contour data associated with the structure
106, for example data obtained by the FCM's
104 and/or the CMM's
108, to design data such as the target contour data
116 to determine if the contours of the structure
106 are consistent with the intended design and any allowed tolerances. The contour control
application
110 also is operative to receive force/load data measured by the FCM's
104. The force/load data can be stored in the memory
202, the CDR
112, or at another data storage device as, for example, the load data
114. This load data
114 may be stored when the contours of the structure
106 are in a desired configuration, such that that another contour control system
100 can replicate the desired contour configurations without having to reanalyze and
measure the surface contours. As explained, this embodiment may be particularly useful
when the structure
106 is manufactured, stored, and/or assembled at more than one facility. The contour
control application
110 also is operative to analyze the actual contour data obtained by the CMM's
108 and/or the force/load data measured at the FCM's
104 to determine if the structure
106 is consistent with a desired design and any associated tolerances.
[0050] The analysis of the target contour data
116, the load data
114, and/or the actual contour data data provided by the CMM's
108 and/or the FCM's
104 can be used by the contour control application
110 to determine if any forces should be applied to the surfaces of the structure
106 to manipulate the structure
106 to correct deviations between the target contour data
116 and the actual contour data associated with the structure
106. In one embodiment, the contour control application
110 relies only upon the load data
114 associated with the FCM's
104 to determine if any forces should be applied to or removed from the structure
106. For example, each FCM
104 can have a calculated target force value and associated tolerances, wherein the target
force values may be calculated for FCM
104 at each FCM
104 location. The target force values are forces that, if applied at the locations associated
with respective FCM's
104, should result in the desired structure contours of the structure
106. Thus, the contour control application
110 monitors the forces applied and/or sensed at each FCM
104 to determine if the forces deviate from the corresponding threshold range of force
values. Once the contour control application
110 determines that a particular force measurement is out of tolerance, or out of a pre-determined
threshold range of force values, then the contour control application
110 is operative to activate the associated FCM
104 to apply or remove force between the FCM
104 and the structure
106 until the force measurement is again within tolerance, or within the pre-determined
threshold range of force values.
[0051] It should be understood that the target force values and corresponding threshold
ranges of acceptable force values can be established using known engineering analysis
tools and techniques such as finite element analysis when the locations for each FCM
104 and the quantity of the FCM's
104 are determined. It should be appreciated that the quantity of FCM's
104, the locations of each of the FCM's
104, the target forces applied by each of the FCM's
104, and the threshold range of acceptable force values for each FCM
104 may be calculated by the contour control application
110 after receiving input regarding the characteristics of the structure
106, for example the target contour data
116 and/or the actual contour data obtained by the CMM's
108 and/or the FCM's
104, or may be input into the contour control application
110 by an authorized entity.
[0052] Turning now to
FIGURE 6, a method
600 for controlling structure contours using the contour control system
100 will now be described in detail. It should be understood that the operations of the
method
600 are not necessarily presented in any particular order and that performance of some
or all of the operations in an alternative order(s) is possible and is contemplated.
The operations have been presented in the demonstrated order for ease of description
and illustration. Operations may be added, omitted, and/or performed simultaneously,
without departing from the scope of the appended claims. It also should be understood
that the illustrated method
600 can be ended at any time and need not be performed in its entirety.
[0053] Some or all operations of the method
600, and/or substantially equivalent operations, can be performed by execution of computer-readable
instructions included on a computer-storage media, as defined above. The term "computer-readable
instructions," and variants thereof, as used in the description and claims, is used
expansively herein to include routines, applications, application modules, program
modules, programs, components, data structures, algorithms, and the like. Computer-readable
instructions can be implemented on various system configurations, including single-processor
or multiprocessor systems, minicomputers, mainframe computers, personal computers,
hand-held computing devices, microprocessor-based, programmable consumer electronics,
combinations thereof, and the like. Thus, it should be appreciated that the logical
operations described herein are implemented (1) as a sequence of computer implemented
acts or program modules running on a computing system and/or (2) as interconnected
machine logic circuits or circuit modules within the computing system. The implementation
is a matter of choice dependent on the performance and other requirements of the computing
system. Accordingly, the logical operations described herein are referred to variously
as states operations, structural devices, acts, or modules. These operations, structural
devices, acts, and modules may be implemented in software, in firmware, in special
purpose digital logic, and any combination thereof. For purposes of illustrating and
describing the concepts of the present disclosure, the method
600 is described as being performed by the contour control system
100, though this embodiment is merely exemplary.
[0054] The method
600 begins at operation
602, wherein the contour control system
100 determines if deformation data associated with the structure
106 has been received. The deformation data indicates how the structure
106 deviates from a desired structure design and can be used by the contour control system
100 to determine how to manipulate the structure
106 to obtain the desired contours. Additionally, or alternatively, the deformation data
can include the load data
114, which can indicate the loads needed at the FCM's
104 to manipulate the structure
106 to obtain the desired contours. As mentioned above, the load data
114 can be received from a manufacturing, assembly, or storage facility, or from an entity
transporting the structure
106. In some embodiments, the load data
114 is generated and/or retrieved from the FCM's
104 of the contour control system
100. Thus, it should be understood that some embodiments of the method
600 are performed by one contour control system
100 and some embodiments of the method
600 are performed by two or more contour control systems
100.
[0055] If the deformation data and/or the load data
114, have not been received, the method
600 proceeds to operation
604, wherein the contour control system
100 determines the actual contour data associated with the structure
106 ("actual contour data"),
i.e., data indicating the location and configuration of the contours of the structure
106, so the contour control system
100 can determine if the structure contours deviate from contours associated with a desired
structure design. Thus, as explained above, the contour control system
100 is operative to measure the structure
106, e.g., to receive and/or retrieve data from the CMM's
108 and/or the FCM's
104 to determine the actual contours of the structure
106. As explained above, the contour control system
100 can obtain the actual contour data from a number of contact and/or contactless measuring
devices including, for example, the FCM's
104 and/or the CMM's
108.
[0056] The method proceeds to operation
606, wherein the contour control system
100 obtains target contour data
116 associated with the structure
106. As explained in detail above, the contour control system
100 is configured to retrieve target contour data
116 indicating the specified contour locations, configurations, and/or associated tolerances.
In some embodiments, the target contour data
116 is stored at a data storage device such as, for example, hard drive, a memory, a
database, a server, or the like, for example the CDR
112. Thus, the operation
606 includes, in some instances, communicating with the CDR
112 to determine if target contour data
116 associated with the structure
106 is available, and retrieving the target contour data
116, if available.
[0057] As illustrated, the method
600 proceeds to operation
608 after operation
606, or after operation
602 if the contour control system
100 determines at operation
602 that the deformation data is available. As explained above, the contour control system
100 is configured to retrieve target contour data
116 indicating the specified contour locations, configurations, and/or associated tolerances.
At operation
608, the target contour data
116 is analyzed by the contour control system
100 to determine forces to apply to the structure
106. For example, the contour control system
100, or a contour control application
110 of the contour control system
100, is operative to compare the retrieved or received shape data to the target contour
data
116 indicating desired design contours for the structure
106 and can determine how to manipulate the structure
106 to obtain the desired contours. In some embodiments, the contour control system
100 is configured to analyze actual contour data that is measured by the FCM's
104, without relying upon measurements collected by the CMM's
108, to determine if the actual contours of the structure
106 deviate from the contours of the targeted design of the structure
106.
[0058] Therefore, it should be understood that the contour control system
100 is operative to analyze actual contour data retrieved from various sensors and measurement
devices, including the FCM's
104 and/or the CMM's
108, to determine if the contours of the structure are consistent with a desired design
and any associated tolerances. Regardless of which measurement devices the contour
control system
100 uses to obtain the actual contour data, the contour control system
100 is configured to retrieve the target contour data
116 from the memory
202 and/or the CDR
112 and comparing the target contour data
116 to the actual contour data.
[0059] Additionally, or alternatively, operation
608 includes, in some embodiments, retrieving load data
114 from the memory
202 and/or the CDR
112, and comparing the load data
114 to the actual contour data in the form of measured force/load data retrieved from
the FCM's
104. By analyzing the various data available to the contour control system
100, the contour control system
100 determines not only if the structure contours are within tolerance of the desired
structure contours, but also the extent to which the structure contours deviate from
the desired structure contours. Thus, the contour control system
100 determines how to manipulate the structure
106 to control the contours of the structure
106 such that the contours of the structure 106 will be within tolerance of the targeted
design contours.
[0060] The method
600 proceeds to operation
610, whereat the contour control system
100 applies the determined forces to the structure
106. In operation
610, the contour control system
100 uses the forces determined in operation
608 to control the FCM's
104. As explained above, the contour control system
100 may inflate one or more air cushion pads of the FCM's
104, deflate one or more air cushion pads of the FCM's
104, increase suction of one or more vacuum cups of the FCM's
104, decrease suction of one or more vacuum cups of the FCM's
104, bring one or more FCM's
104 into or out of contact with the structure, or adjust the position of one or more
FCM's
104. Thus, at operation
610, the contour control system
100 applies any forces determined by the contour control system
100 to be needed to adjust the contours of the structure 106. It should be understood
that the forces needed to adjust the contours of the structure
106 may be obtained from deformation data passed to the contour control system
100 from another entity and/or determined by the contour control system
100, for example, as determined in operation
608 or in accordance with other operations.
[0061] The method
600 proceeds to operation
612, wherein one or more assembly, manufacturing, or other operations are performed on
the structure
106. For example, two structures
106 may be mated together while the respective contours of the structures
106 are adjusted to the desired configurations. Because the respective contours of the
structures
106 may be controlled, the assembly, manufacturing, and/or other operations may be simplified
and additional labor may be avoided. For example, in some applications, the mating
of two or more fuselage sections of an aircraft requires that the two fuselage sections
be similarly configured. During transit of the fuselage sections, the surface contours
of the sections may move, complicating the mating steps. Thus, assembly facilities
may include shim production facilities such that gaps between the mated components
may be minimized and/or eliminated. To the contrary, manufacturing facilities employing
a contour control system
100 such as that disclosed herein may be able to manipulate the respective components
such that less manpower and/or materials are needed to complete the assembly operations.
These and other operations associated with assembling, machining, manufacturing, and/or
transporting the structure
106 may be simplified, and/or the costs and time required to perform these operations
may be reduced, using the methods and systems disclosed herein.
[0062] In some embodiments, the method proceeds to operation
614, wherein the contour control system
100 verifies the structure contours,
i.e., the contour control system
100 can determine if the shape of the structure
106 is consistent with the desired contours and associated tolerances of a desired structure
106. As mentioned above, not all operations are required, and it is possible and contemplated
that the verification process of operation
614 may be omitted or skipped based upon a determined process accuracy and/or precision,
as well as other factors. Although not illustrated in
FIGURE 6, the contour control system
100 is configured to store load data
114 at any time. For example, the contour control system
100 can store the load data
114 when the contours of the structure
106 are determined to be consistent with the desired structure contours and the associated
tolerances. At such a time, or at any time when prompted by an operator or trigger
condition, the loads associated with all FCM's
104 can be stored as load data
114. As explained above, the load data
114 can be stored at the memory
202, the CDR
112, and/or another data storage device. If the structure
106 is transported to another entity, the load data
114 may be transported with the structure
106 and/or stored in a data storage device accessible by the other entity. The method
600 ends.
[0063] Although not described in detail above, the contour control system
100 is configured to continuously monitor and control the contours of the structure
106. Thus, the devices and methods described above may be continuously employed to maintain
the structure
106 in the targeted configuration during a particular operation,
e.g., an assembly, machining, manufacturing, and/or transportation operation. In the example
of an aircraft fuselage, it will be appreciated that additional structures and components
may be added to the structure
106. For example, flooring, stringers, attachment mechanisms, doors, windows, wiring,
wiring harnesses, electronics, plumbing, seating, trim, other structures, combinations
thereof, and the like, may be added. These components contribute weight to the structure
106 and adding these structures to the structure
106 may alter the shape or configuration of the structure
106. Thus, the ability to continuously monitor and adjust the FCM's
104 to maintain the structure
106 in the desired configuration may greatly reduce the variations sometimes experienced
in aircraft fuselage manufacturing, assembly, and/or other operations. As mentioned
above, the load data 114 associated with the FCM's
104 can be stored at any time and can be passed to another entity. Thus, after a manufacturing,
assembly, or other operation, the structure
106 may be transported to another entity that can access the load data
114. Therefore, the other entity will have the ability to return the structure to the
desired shape with little effort, instead simply importing the load data 114 to the
contour control system
100 and applying that load data
114 to the structure
106.
[0064] Based on the foregoing, it should be appreciated that systems and methods for controlling
the contours of a structure
106 and monitoring and controlling forces applied to the structure
106 to control the contours of the structure
106 are provided herein. Although the subject matter presented herein has been described
in language specific to computer structural features, methodological acts, and computer
readable media, it is to be understood that the invention defined in the appended
claims is not necessarily limited to the specific features, acts, or media described
herein. Rather, the specific features, acts and media are disclosed as example forms
of implementing the claims.
[0065] The subject matter described above is provided by way of illustration only and should
not be construed as limiting. Various modifications and changes may be made to the
subject matter described herein without following the example embodiments and applications
illustrated and described, and without departing from the true spirit and scope of
the present disclosure, which is set forth in the following claims.